Versatile Termination Method for Long Cables

ABSTRACT

A method for creating a composite cable having at least one advanced termination on at least one end. An advanced termination is added to an end of a short synthetic tensile strength member. The strength of the tensile strength member and termination is then tested. Once tested satisfactorily, the short cable is spiced onto a long cable of the same type using prior art splicing techniques. The union of the short cable and the long cable creates a “composite” cable having a advanced termination on at least one end. In most applications it is preferable to set the length of the short cable so that the interwoven splice will exist at a desired location.

CROSS-REFERENCES TO RELATED APPLICATIONS

This non-provisional patent application claims the benefit of anearlier-filed provisional application. The first provisional applicationwas assigned serial number 61/934,170. It listed the same inventors.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

MICROFICHE APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of tensile strength members. Morespecifically, the invention comprises a method for creating a longtensile strength member with an advanced termination or terminationsthat can be pre-tested using equipment that is limited to testingshorter tensile strength members.

2. Description of the Related Art

Tensile strength members must generally be connected to other componentsin order to be useful. A flexible cable provides a good example. Thecable must generally include some type of end-fitting so that it cantransmit a load, For example, a cable used in a hoist generally includesa lifting hook on its free end. This lifting hook may be rigged to aload. The assembly of an end-fitting and the portion of the cable towhich it is attached is generally called a “termination.”

A tough steel lifting hook is commonly attached to a wire rope to createa termination. A “spelter socket” is often used to create such atermination. The “spelter socket” includes an expanding cavity withinthe end-fitting. A length of the wire rope is slipped into this cavityand the individual wires are splayed apart. A liquid potting compound isthen introduced into the expanding cavity with the wires in place. Theliquid potting compound transitions to a solid over time and therebylocks the wire rope into the cavity.

The potting compound used in a spelter socket is traditionally moltenlead and—more recently—is more likely a high-strength epoxy. However,the term “potting compound” as used in this description means anysubstance which transitions from, a liquid to a solid over time.Examples include molten lead, thermoplastics, UV-cure or thermosetresins (such as two-part polyesters or epoxies). Other examples includeplasters, ceramics, and cements. The term “solid” is by no means limitedto an ordered crystalline structure such as found in most metals. In thecontext of this invention, the term “solid” means a state in which thematerial does not flow significantly under the influence of gravity.

Terminations on wire rope are quite common in hoists and cranes. Theseterminations are well understood and their performance and reliabilityhave been established over many decades. In recent years the opportunityto replace wire rope cables with modern, high-strength synthetic cableshas arisen. Many different materials are used for the filaments in thesesynthetic cables. These include KEVLAR, VECTRAN, PBO, DYNEEMA, SPECTRA,TECHNORA, ZYLON, glass fiber, and carbon fiber (among many others). Ingeneral the individual filaments have a thickness that is less than thatof human hair. The filaments are very strong in tension, but they arenot very rigid. They also tend to have low surface friction. They arequite different from steel wires.

Terminations, are used for synthetic filament cables, but they assume adifferent form than those used for wire rope. Synthetic filament cablestend to be made by braiding multiple strands together. While theindividual filaments are made using various modern processes, theconstruction of the cable itself tends to follow the patternsestablished for natural-fiber ropes many years ago. Perhaps notsurprisingly, the methods used to create a termination tend to followthe old patterns for ropes as well.

FIGS. 1-2 shows a traditional method for adding a termination to one endof a synthetic cable. Cable 10 is made from advanced high-strengthsynthetic filaments. It is known to join multi-stranded cables usingweaving or splicing methods. In these methods, connections are made byinterweaving strands of one section of cable with strands of anothersection of cable (sometimes the sections lie in the same cable andsometimes they do not).

FIG. 1 shows an exemplary prior art operation. Cable 10 includes eightindividual strands of synthetic filaments. Each strand may containthousands or even millions of individual filaments, but the prior artweaving operations do not typically break the cable down beyond thestrand level. The depiction of cable 10 is representative rather thanentirely accurate. The example shown has 8 separate strands. The strandswould typically be interwoven with 2 pairs of strands in a left-handhelix and two pairs in a right-hand helix.

The objective of the example shown in FIGS. 1 and 2 is to weave a lengthof the cable back on itself to form an “eye” on the cable's end.Considerable mechanical skill and dexterity is required to form an eyeon the end of a cable and in other instances to join lengths of cabletogether. However, persons having these skills are commonly found inindustries where large cables are used. Further, the strength andreliability of cable splices made by such persons are well understoodand accepted. As a result, it is readily accepted that these provenmethods of connection do not require protesting and can even be done inthe field, in a non-controlled environment, by trained personnel. Thisis even true for critical applications. This has been the standardmethod of termination since inception, and it make up over 99% of theentire industry of long synthetic fiber cables. Thus, there isconsiderable standardization, knowledge, and field support for such amethod of termination.

In FIG. 1, a length of strands proximate the cable's end is unwoven tocreate separated strands 14. The end of the cable is bent into a loop orbight, sometimes around a reinforcing element such as thimble 12. FIG. 2shows the continuation of the operation. The weave of the strands withinthe cable is loosened so that separated strands can be threaded backinto the cable in a prescribed pattern. Interwoven section 24 is therebycreated. The loose ends of separated strands 14 are typically cut off(after a sufficiently long interwoven section 24 has been created) andtaped or otherwise secured.

The result is eye splice 16 on one end of cable 10. When produced bytrained personnel, the eye splice does work and it is considered anefficient and reliable means of termination, in this context the termefficiency means the ratio of the breaking stress of the complete cablewith the termination attached versus the breaking stress of the cablewithout a stressed area such as in the middle of the cable. A perfectlyefficient cable would have an efficiency of 100%, including thetermination. On synthetic fiber cables, achieving this or nearly thisefficiency is commonly possible with many forms of prior art splices.

Although the eye splice is strong, it is ill-suited to manyapplications. For example, while one could use an eye splice to attach alifting hook to the end of a hoist line, the eye splice is unable towithstand battering forces very well. In addition, the diameter of theeye splice will be too large in many instances. It would be advantageousto instead connect a hook or other device directly to the syntheticcable, analogous to the way a spelter socket is connected to a wirerope. Fortunately, the technology to create such terminations exists.

The prior art approaches to adding a termination to a synthetic cableare explained in detail in commonly-owned U.S. Pat. No. 7,237,336, whichis hereby incorporated by reference. The terminations can be added tothe cable as a whole or some sub-component of the cable such as astrand. Commonly-owned U.S. Pat. No. 8,371,015 explains how multipleterminations may be attached to multiple strands of a larger cable. Thistoo is incorporated by reference.

In order to gain a strong and repeatable result, the addition of atermination directly to a synthetic cable must generally be done underhighly controlled conditions such as found in a factory. This isparticularly true of medium to large end fittings configured for a cablehaving an overall diameter of greater than 20 mm and sometimes beingconsiderably larger. In fact, those skilled in the art recognize thatterminating larger synthetic cables is exceptionally difficult to masterin even a highly controlled environment. Unlike most metal strengthmembers, achieving an efficient and repeatable result requires verystringent control of the process, highly skilled personnel and preciseprocessing.

An end-fitting is commonly attached to a larger synthetic filament cableby use of a potting compound. Liquid potting compound (such as an epoxyor a polyester) is added to a cavity in the fitting after a length offilaments has been placed within the fitting. It is preferable to holdthe components in a stable configuration while the potting compoundcures—which may take 12 hours or more. Temperature and other variablesare preferably controlled during this process, as are the properties ofthe potting compound itself. The potting compound may be added to thecavity in a variety of ways, including pre-wetting, infusing, etc.

The process of attaching an end fitting to a synthetic cable produces awider performance variation than is typical for steel cables or forspliced techniques on synthetic cables. In fact, the creation of anadvanced termination on an end of a synthetic cable will often representthe weakest link in the whole system. As such, in many instances it willbe necessary to lest the strength of the completed termination before itis used.

Exemplary applications include hoisting cables and mooring cables wherea known and predictable strength is very important. This requirementcreates challenges in the field of synthetic-filament cables sinceconventional tensile testing equipment used in the industry is (1)limited in length and (2) limited in length. A typical large test framecan pull loads of about 1,000 tons. The length, of such a test frame isonly about 20 meters though. Longer test frames do exist (some over 100meters) but they are very rare. When tensile members are made longerthan the length of the readily available test, frame, they are rarelyable to be tested properly given the practical constraints that exist inindustry. This creates limitations on what can be tested and impactslogistics on any large or remotely used tensile members requiringspecialty terminations.

It is desirable to use synthetic filament cables to replace steel andother conventional cables, bat In order to do so the synthetic filamentcables must have an equivalent useful length. Many large diameterapplications are well beyond the typical test bed length, such as 500 oreven 1,000 meters as an example. In fact, most large and/or long cableswill not fit in any test bed in the world. This complication does notpresent a serious issue for existing steel or synthetic cables usingconventional technology because highly standardized methods and deviceshave been developed and proven to be reliable over the last century.

By comparison, it is not commonly possible to achieve a the same levelof efficiency, reliability, and repeatability with many of the morecompact, mechanical, versatile synthetic cable methods of terminationsuch as porting sockets, resin terminations, composite terminations, orspike and cone type frictional arrangements, etc. These types ofterminations tend to put far greater stresses in a smaller area, meaningthere is much less room for operator error and the efficiency car oftenbe reduced if not handled properly. Further, these types of terminationson synthetic cables have by comparison a limited history, limited use,limited standardization and training, and introduce a significantlygreater need for control over the process in order to achieve arepeatable result.

On a synthetic cable, known splicing techniques may not be suitable forlong lines and are often not be ideal from a termination perspective.For example, there is often a need for a termination analogous to thoseused for wire rope, Examples include termination with a hard end such asa hook, a threaded stud, a small eye, or a clevis on the end of aspelter or resin socket, etc. Such hard, versatile, and generallycompact ends are well known and thus a desirable option in mostindustries where large and/or long cables are used. As an example, anoffshore steel crane wire would typically have a very compact, pottedsocket made from steel and including a clevis or eye connection. As withsplices used for synthetic fiber cables, these versatile forms ofterminations are well established, standardized, trusted, and producedin the field with technicians that are trained in the process. Thereforehigh load testing in a proofing bed is not generally necessary. However,when considering a high performance synthetic cable, spliced eyes do notprovide the same level of functionality or versatility as those fromless proven methods.

The proposed method creates a safe and reliable means to apply andvalidate the performance (pre-test) of a more desirable termination onsuch long synthetic cable applications. FIG. 3—a sectional view—shows anexample of an advanced termination. Anchor 18 includes an internalcavity 20. A length of strands from cable 10 is placed within thiscavity. Preferably the strands are splayed apart in some form ofexpanding cavity (though other techniques may be used). A liquid pottingcompound is placed within the cavity (either before, during, or afterthe strands are added).

The liquid potting compound transitions to a solid over time to createpotted region 22. Once solidified as shown, the strands within pottedregion 22 are locked in place and anchor 18 is secured to the end of thecable. Some feature for transmitting a load to the cable is typicallyincluded. In this example loading feature 21 assumes the form of a loop.

Other classes of advanced terminations can be made without using apotting compound to secure the cable strands to the anchor. FIG. 10shows an assembly that is commonly referred to as a “spike and cone”termination. A length of strands is splayed apart in cavity 20 as forthe potting example. However, rather than using potting compound, theyare mechanically secured. Cone 62 is introduced into the center of thestrands. Compression plug 64 is then screwed into the open end of anchor18 via threaded engagement 66. The strands are then mechanically clampedin place.

It is possible to combine the prior art approaches—such as by usingpotting compound in the spike-and-cone configuration of FIG. 10, Inaddition, anchor 18 can be made quite tough. As an example, the anchormay be made of stainless steel so that it can endure an abusiveenvironment. Such a termination, is advantageous in many instances wherea synthetic cable might be used to replace wire rope or other moretraditional materials.

Countless forms of synthetic fiber cable terminations can be conceived,including those made entirely of composites for example. Any suchversatile termination that is not a splice, and especially those whichare more compact in nature, have many potential limitations as coveredpreviously. These limitations create the absolute need for production ina controlled setting (which is not in the field).

Given the above, the present industry issue exists: Large ropes areutilized in the field, often in remote areas, and they often need to bere-terminated. Going back to the offshore crane example, if a crane lineis damaged in the ocean, there must be an immediate remedy to get hackto work. Removing the line and shipping the cable to its originalfactory for re-termination is not a feasible option. Reliable fieldtermination of many forms exist for steel wire today, hut they do notexist for synthetic cable. If using a synthetic cable and thetermination is anything other than a splice, it requires both acontrolled setting and most often proof testing to ensure safe andreliable use. This very fact has prevented synthetic cables from beingutilized where a more versatile or compact termination is needed. Thepresent invention presents a solution to this problem, among otherproblems.

BRIEF SUMMARY OF THE PRESENT INVENTION

The present invention comprises a method for creating a composite cablehaving at least one advanced termination on at least one end. Anadvanced termination is added to an end of a short synthetic tensilestrength member. The strength of the tensile strength member andtermination is then tested. Once tested satisfactorily, the short cableis spliced onto a long tensile member of a comparable type using priorart splicing techniques. The union of the short tensile member and thelong tensile member creates a “composite” cable having an advancedtermination on at least one end. In most applications it is preferableto set the length of the short cable so that the interwoven splice willexist at a desired location.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view, showing the creation of a prior art eyesplice.

FIG. 2 is a perspective view, showing the continuation of the operationof FIG. 1.

FIG. 3 is a sectional elevation view, showing the addition of a advancedtermination to one end of a synthetic cable.

FIG. 4 is a perspective view, showing a terminated short cable madeaccording to the present inventive process.

FIG. 5 is a perspective view, showing a composite cable made accordingto the present invention.

FIG. 6 is an elevation view, showing an exemplary test rig used to testa short cable made according to the present invention.

FIG. 7 is an elevation view, showing an inventive cable in use on anoffshore oil platform.

FIG. 8 is an elevation view, showing an inventive cable being used tohoist a load out of the water.

FIG, 9 is an elevation view, showing an inventive cable being used on amining dragline crane.

FIG. 10 is a sectional elevation view, showing another type of advancedtermination.

REFERENCE NUMERALS IN THE DRAWINGS

-   10 cable-   12 thimble-   14 separated strands-   16 eye splice-   18 anchor-   20 cavity-   21 loading feature-   22 potted region-   24 interwoven section-   26 short cable-   28 drum-   30 test loading device-   32 oil platform-   34 crane-   35 boom-   36 composite cable-   38 sea surface-   40 sea floor-   42 payload-   44 max hook height-   46 lower splash boundary-   48 drum-   50 top sheave-   52 dragline crane-   54 boom-   56 lifting crane-   58 dragging cable-   60 bucket-   62 cone-   64 compression plug-   66 threaded engagement

DETAILED DESCRIPTION OF THE INVENTION

The present invention applies to virtually any type of tensile strengthmember using synthetic filaments as the core load bearing elements. Thiswould include common device terms such as ropes, cables, cords, etc.Cables are used as examples of elastic strength members in theembodiments described. While the present invention is not applicable tosteel wire cables, it is highly applicable to synthetic fiber cablesthat are used principally for load-bearing purposes, and the like.

The main concept of the invention is to create a “short” tensilestrength member with one or more advanced terminations attached. Theterm “advanced termination” is defined to mean any component that can beattached directly to a synthetic cable without using interweavingtechniques. The term includes anchors attached by potting a length offilaments into an internal cavity and spike-and-cone type anchors, amongothers. The “short” assembly is tested so that its useful working loadis known for certain. The “short” assembly is then joined to a “long”tensile strength member using prior art interweaving techniques. Theresult is a composite cable whose overall performance is known by (1)the results of the testing done on the “short” assembly, and (2) yearsof accumulated practical understanding of the performance of interwovensplices. The terms “short” and “long” are of course vague and they willbe defined in the context of the invention.

FIG. 4 shows two components of a composite cable before they are joinedtogether. Short cable 26 includes a advanced termination, that has beenattached to one end as described previously. Cable 10 in this example isa “long cable” with no attached hardware. In this example both cablesare made of braided strands. The drawing does not depict the braidedconstruction completely accurately, since it is quite complex, but thelines show that some of the braid components are twisted in onedirection and some are twisted in the opposite direction.

It is possible using prior art techniques to create an interwoven,interlocking, or otherwise gripping splice between these two pieces ofcable. FIG. 5 shows the two cable segments joined together by aninterwoven splice. Short cable 26 and long cable 10 are joined togetherby interwoven section 24. The result is a much longer “composite” cable.

The terms “short” and “long” are relative to each other. A typical“short” cable might range from as short as 5 meters to as long as 100meters. In some rare cases this may be even longer. A “long” cable mightrange from 50 meters up to several km in length. When the terms “short”and “long” are used in this description, the reader should understandthat the “long” cable is typically 4 or more times longer than the shortcable. The determination of the length of each component is oftendictated by the availability of testing equipment for evaluating theperformance of the short cable, and the actual application, as will beexplained subsequently.

A detailed explanation of the prior art interweaving techniques used incable splices is beyond the scope of this disclosure, but the reader maybenefit from some general explanation. An interwoven splice isapplicable to any synthetic tensile strength member made of multiplestrands, so long as the strands are arranged in some ordered fashion.Cable strands are generally braided, twisted, or layed in a helicalfashion. Generally, however braids such as a twelve strand are mostcommon due their ease of splice-ability. A permanent joint can becreated between two cables (or two parts of a single cable) by partlyuntwisting the strands and then interweaving them. Interwoven splicescan be used to form a loop or eye on and end of a cable. They may alsobe used for joining the ends of two cables together (either directly orby forming an eye on one cable end that is interlocked with an eye onthe other cable end).

In general, a section of completely unwoven strands are created on theend of one cable and a section of loosened (yet not unwoven) strands arecreated on the end of a second cable. The completely unwoven strands onthe first cable are then woven into the voids between the loosenedstrands on the second cable in a prescribed and repetitive fashion. Aspecified number of weaves are created. Any excess material from theunwoven, strands of the first cable is then removed and the free endsare secured by any suitable method, such as taping or whipping.

The creation of a proper interwoven splice is a skilled job that iscustomarily carried out by a trained rigging specialist. Fortunately,such specialists are common within the industries needing high-strengthsynthetic fiber cabling. When properly done, an interwoven splice can becapable of maintaining the cable's full breaking strength.

The interweaving techniques are very old, as most were developed in theage of sailing ships. The performance of such interwoven splices is wellunderstood and perhaps as importantly—very well trusted within theindustries where they are used. Readers wishing to know more of thedetails of accepted interwoven splicing techniques are referred to TheSplicing Handbook, 2^(nd) Edition, published by international Marine(ISBN 0-07-135438-7).

Terminations such as shown in FIGS. 3 and 10 are preferably createdunder controlled conditions. This will typically be a factory productionfacility, though a smaller scale facility could be set up to handle itas well. In the case of a potted termination, cable and anchor alignmentis preferably maintained over the cure time of the potting compound.This may take a day or even longer. In addition, the strand alignmentwithin the cable also dictates the creation of a constrained length ofcable extending out of the anchor.

Potting compound mix ratios are important, as are other factors such asthe ambient temperature. Preferably many conditions are controlled inorder to create a strong and repeatable result. Even with the bestprocess controls, however, these less conventional, compact forms ofterminations are inherently less proven and much more susceptible tobreaking efficiency loss and general breaking scatter due to processinginconsistencies or errors. Thus a critical element of quality controlfor such terminations is the proof testing process, and this isespecially needed on critical applications such as lifting, securing,towing, mooring, etc.

FIG. 6 schematically depicts one of many possible testing rigs for ashort cable 26 with an attached anchor 18. Cables made of syntheticfilaments tend to have low surface friction and are not easy to grip. Itis often important to apply very high tensile loads in the test. In manyeases this will be a significant fraction, of the calculated breakingstrength of the cable. Thus, it is often not possible to apply thisamount of tension through a fixture that simply grips the cable'sexterior. Likewise, it is not desirable to knot a portion of the cablearound a loading fixture since the knot: will drastically reduce thecable's strength.

FIG. 6 shows one end of short cable 26 being wrapped around drum 28. Itis possible to wrap several turns of the cable around a drum of suitablediameter and thereby secure the cable's free end without over-stressingit. Test loading device 30 is attached to anchor 18 using a hook orsimilar feature. Tension may then be applied through test loading device30 while drum 28 is held in position. In another version, test loadingdevice 30 could be held in a fixed position while torque is applied tothe drum. Other testing fixtures are obviously possible and are by nomeans limiting.

Alternately as could be imagined by those skilled in the art, if theshort cable is able to be tested within the load frame, a dummy orsacrificial end such as a spliced eye or potted termination could beapplied to the opposing end. In such a case a conventional fixed pointcable could be used in place of the drum, and this dummy or sacrificialend could then be removed if desired.

However loaded, the result of the test is that the cable can becertified as having been loaded to a specified amount with no problemresulting. Any defect in the manufacturing of the components or theassembly process may thereby be reliably detected.

Returning now to FIG. 5, the reader will recall that short cable 26 isjoined to long cable 10 using known interweaving (“splicing”)techniques. When properly executed, interwoven section 24 will have abreak strength equal to or greater than the break, strength of the cableitself As explained previously, the break strength of the advancedtermination (created by attaching anchor 18), depending on the designand method of manufacturer, will commonly be somewhat less than thebreak strength of the cable (though possibly quite close).

Thus, in the assembly of FIG. 5 the “weak link” is the terminationpoint. However, the termination has been tested (such as by the rig ofFIG. 6) and certified to exceed a specified break strength. Thus, theassembly as a whole in FIG. 5 (a “composite cable”) may be certified ashaving a break strength in excess of the tested amount.

At this point it may be natural to wonder why a composite cable isneeded and ask instead why one would not simply attach the anchor to oneend of long cable 10 and dispense with the need for the interweavingprocess. There are several reasons why such an approach would beundesirable. First, long cable 10 is often extraordinarily long. It isnot unusual for such a cable to be 15,000 meters or more in length. Sucha cable is often rolled onto a large and heavy drum. It is not a simplematter to move such a large cable and bring it into a controlledfacility for the addition of an anchor.

Second, it is generally true that a test such as shown in FIG. 6 must becarried out by a device on one end of the cable that engages the anchorand a device on the other end that engages the free end of the cable.Thus, the length of the cable being tested determines the length of theapparatus required to test it. For example, it is not preferable toengage a synthetic cable at some mid-point and then apply considerabletension. The test of FIG. 6 shows the free end of the cable beingwrapped around a drum and secured. Five or ten turns may be needed toadequately secure the cable to the drum. Applying the drum-wrap at themid-point of the cable would likely produce slippage between the cablestrands and a degradation of the cable's performance. Thus, the cable ispreferably tested by holding it at its ends and applying tension.

Therefore, the distance between the drum and the test loading device 30will determine the length of the cable that can be tested, A largefacility might have a test fixture that is 50 meters in length, but alonger fixture is rare. It is also not generally feasible to have a“mobile” end point such as a moving vehicle. Static testing of suchcables often requires huge tensile forces—such as 250,000 pounds. Novehicle remains stationary during the application of such a force. Evenstatic structures must be carefully designed to withstand such forces.

Since one of the significant features of the present invention is theactual testing of the advanced termination, it is important for shortcable 26 to have only a moderate length. Preferably it is less than 100meters in length and may in fact be much shorter. The length selectedfor short cable 26 will of course determine the location of theinterwoven section.

Returning now to FIG. 5, the reader will note that interwoven section 24is thicker than the other portions of the composite cable. This addedthickness can cause problems when running the interwoven section overpulleys or other devices. Thus, the location of the interwoven sectionis preferably considered when creating a composite cable. The pulleysand other feeding devices can be designed to accommodate the addedthickness of interwoven section 24. However, it is generally undesirableto have interwoven section 24 pass around a pulley or other bend whileit is heavily loaded.

FIG. shows one representative application for a composite cable madeaccording to the present invention. Crane 34 is mounted on offshore oilplatform 32, well above sea surface 38, Composite cable 36 extends downinto the water where it is connected to pay load 42 resting on sea floor40. In this simple example, sea floor 40 might lie at a depth of 3,000meters below sea surface 38. It is apparent from this diagram that theinterwoven section of composite cable 36 lies well underwater at thispoint and in fact will be quite close to sea floor 40.

However, when the crane reefs in composite cable 36 the interwovensection will be pulled up toward the surface. FIG. 8 shows a closer viewof crane 34. Crane 34 includes drum 48 which is used to pay off and reelin composite cable 36. Boom 35 mounts tip sheave 50, over which thecable passes. Max hook height 44 represents the maximum height to whichthe crane can lift the payload.

As those skilled in the art will know, the load imposed on the cable bypayload 42 varies substantially depending upon whether the payload isimmersed in the sea or lifted clear into the air. The weight of anobject immersed in water is reduced by the weight of the volume of waterdisplaced by the object. This concept is generally referred to asArchimedes' Principle. For a typical solid structure, its weight inwater is less than ½ its weight in air.

Crane designers working in offshore applications carefully considerArchimedes' Principle. The water's surface is not stationary in offshoreapplications but rather moves with each passing swell. Thus, there isoften not a clearly defined surface level. Instead, the engineers referto a “splash zone” having a lower boundary and an upper boundary. Theyconsider that the payload could be lifted, tree of the water anywherewithin this “splash zone.”

It is the lower extreme of the splash, zone that is often mostimportant. Lower splash boundary 46 is shown in FIG. 8. At any time thatpayload 42 is lifted above this height it might in fact be free of thewater and the composite cable would then be subjected to the foil weightof the payload in air.

Designers in this off-shore application might decide that the interwovensection of the composite cable needs to be on drum 48 before payload 42is lifted above lower splash boundary 46. They may further conclude thatthe interwoven section needs to have five turns on the drum betweenitself and the paid off portion of the cable when payload 42 is liltedabove lower splash boundary 46. These criteria represent examples ofdesign constrains that determine the length of short cable 26 in aparticular application.

Other designers working in a similar environment might prefer that theinterwoven section never pass through top sheave 50. In that case theshort cable length would be determined as the length necessary toprovide adequate lifting height for the payload while keeping theinterwoven section below top sheave 50.

FIG. 9 shows a different application with different selection criteria.Mining dragline crane 52 has a large boom 54 with an attached top sheave50. Lifting cable 56 passes through top sheave 50 and down to bucket 60.Dragging cable 58 pulls bucket 60 toward the crane's cab during thedigging cycle.

In this example interwoven section 24 is located far enough above anchor18 to prevent its failing into the very hostile environment existingaround the bucket and its associated rigging. However, interwovensection 24 is also located low enough so that it is never pulled overtop sheave 50 during the normal operation of the dragline crane.Alternatively, the interwoven section might be located so that it alwaysremains between top sheave 50 and the drum located in the body of thedragline crane.

The reader will thereby perceive the advantages offered by a compositecable constructed of a short cable with an attached advanced terminationthat is connected to a long cable. Additional optional features andcombinations include:

1. Attaching a short cable with an advanced termination to both ends ofa long cable;

2. Attaching a short, cable to a long cable using interlocking eyesplices as shown in FIG. 2; and

3. Attaching a short cable to a long cable using other known and trustedtechniques.

Although the preceding description contains significant detail, itshould not be construed as limiting the scope of the invention butrather as providing illustrations of the preferred embodiments of theinvention. Those skilled in the art will be able to devise many otherembodiments that carry out the present invention. Thus, the languageused in the claims shall define the invention rather than the specificembodiments provided.

1. A method of creating a composite cable with an advanced terminationon one end, wherein the performance of said advanced termination ispre-qualified, comprising: a. providing a short, cable, having a firstend and a second end; b. locking said second end of said short cableinto said advanced termination; c. applying a defined test load to saidshort cable, wherein said defined test load is applied through saidadvanced termination in order to determine whether said short cable andsaid advanced termination pass a defined test criterion; d. providing along cable, having a first end and a second end; and e. after said shortcable passes said defined test criterion, joining said first end of saidshort cable to said second end of said long cable to form said compositecable having a advanced termination on one end.
 2. A method of creatinga composite cable as recited in claim 1, wherein said high-performancetermination comprises an anchor that is locked to said second end ofsaid short cable by potting.
 3. A method of creating a composite cableas recited in claim 1, wherein said high-performance performancetermination comprises an anchor that is locked to said second end ofsaid short cable using a spike and cone connection.
 4. A method ofcreating a composite cable as recited in claim 1, wherein said joiningof said first end of said short cable to said, second end of said longcable is performed by interweaving a section of said short cable intosaid long cable.
 5. A method of creating a composite cable as recited inclaim 2, wherein said joining of said first end of said short cable tosaid second end of said long cable is performed by interweaving asection of said short cable into said long cable.
 6. A method ofcreating a composite cable as recited in claim 3, wherein said joiningof said first end of said short cable to said second end of said longcable is performed by interweaving a section of said short cable intosaid long cable.
 7. A method of creating a composite cable as recited inclaim 1, further comprising: a. providing a second short cable, having afirst end and a second end; b. providing second advanced termination; c.locking said second end of said second short cable into said secondhigh-performance termination; d. applying a defined test load to saidsecond short cable, wherein said defined test load Is applied throughsaid second advanced termination in order to determine whether saidsecond short cable and said second advanced termination pass a definedtest criterion; and e. after said second short cable passes said definedtest criterion, joining said first end of said second short cable tosaid first end of said long cable.
 8. A method of creating a compositecable as recited in claim 2, further comprising: a. providing a secondshort cable, having a first end and a second end; b. providing secondadvanced termination; c. locking said second end of said second shortcable into said second high-performance termination; d. applying adefined test load to said second short cable, wherein said defined testload is applied through said second advanced termination in order todetermine whether said second short cable and said second advancedtermination pass a defined test criterion; and e. after said secondshort cable passes said defined test criterion, joining said first endof said second short cable to said first end of said long cable.
 9. Amethod of creating a composite cable as recited in claim 2, furthercomprising: a. providing a second short cable, having a first end and asecond end; b. providing second advanced termination: c. locking saidsecond end of said second short cable into said second high-performancetermination; d. applying a defined test load to said second short cable,wherein said defined test load is applied through said, second advancedtermination in order to determine whether said second short cable andsaid second advanced termination pass a defined test criterion; and e.after said second short cable passes said defined test criterion,joining said first end of said second short cable to said first end ofsaid long cable.
 10. A method of creating a composite cable as recitedin claim 6, further comprising: a. providing a second short cable,having a first end and a second end; b. providing second advancedtermination; c. locking said second end of said second short cable intosaid second high-performance termination; d. applying a defined testload to said second short cable, wherein said defined test load isapplied through said second advanced termination in order to determinewhether said second short cable and said second advanced terminationpass a defined test criterion; and e. after said second short cablepasses said defined test criterion, joining said first end of saidsecond short cable to said first end of said long cable.
 11. A method ofcreating a composite cable with a advanced termination on one end,wherein the performance of said advanced termination is pre-qualified,comprising: a. providing a short cable, having a first end and a secondend; b. creating a advanced termination on said second end of said shortcable by attaching an anchor to said second end of said short cable; c.applying a defined test load to said short cable, wherein said definedtest load is applied through said anchor in order to determine whethersaid short cable and said advanced termination pass a defined testcriterion; d. providing a long cable, having a first end and a secondend: and e. after said short cable passes said defined test criterion,joining said first end of said short cable to said second end of saidlong cable to form said composite cable having a advanced termination onone end.
 12. A method of creating a composite cable as recited in claim11, wherein said high-performance termination comprises an anchor thatis locked, to said second end of said short cable by potting.
 13. Amethod of creating a composite cable as recited in claim 11, whereinsaid high-performance termination comprises an anchor that is locked tosaid second end of said short cable using a spike and cone connection.14. A method of creating a composite cable as recited in claim 11,wherein said joining of said first end of said short cable to saidsecond end of said long cable is performed by interweaving a section ofsaid short cable into said long cable.
 15. A method of creating acomposite cable as recited in claim 12, wherein said, joining of saidfirst end of said short cable to said second end of said long cable isperformed by interweaving a section of said short cable into said longcable.
 16. A method of creating a composite cable as recited in claim13, wherein said joining of said first end of said short cable to saidsecond end of said long cable is performed by interweaving a section ofsaid short cable into said long cable.
 17. A method of creating acomposite cable as recited in claim 11, further comprising: a. providinga second short cable, having a first end and a second end; b. providingsecond advanced termination; c. locking said second end of said secondshort cable into said second high-performance termination; d. applying adefined test load to said second short cable, wherein said defined lestload is applied through said second advanced termination in order todetermine whether said second short cable and said second advancedtermination pass a defined test criterion; and e. after said secondshort cable passes said defined test criterion, joining said first endof said second short cable to said first end of said long cable.
 18. Amethod of creating a composite cable as recited in claim 12, furthercomprising: a. providing a second short cable, having a first, end and asecond end; b. providing second advanced termination; c. locking saidsecond end of said second short cable into said second high-performancetermination; d. applying a defined test load to said second short cable,wherein said defined test load is applied through said second advancedtermination in order to determine whether said second short cable andsaid second advanced termination pass a defined test criterion; and e.after said second short cable passes said defined test criterion,joining said first end of said second short cable to said first end ofsaid long cable.
 19. A method of creating a composite cable as recitedin claim 12, further comprising: a. providing a second short cable,having a first end and a second end; b. providing second advancedtermination; c. locking said second end of said second short cable intosaid second high-performance termination; d. applying a defined testload to said second short cable, wherein said defined test load isapplied through said second advanced termination in order to determinewhether said second short cable and said second advanced terminationpass a defined test criterion; and e. after said second short cablepasses said defined test criterion, joining said first end of saidsecond short cable to said first end of said long cable.
 20. A method ofcreating a composite cable as recited in claim 16, further comprising:a. providing a second short cable, having a first end and a second end;b. providing second advanced termination; c. locking said, second end ofsaid second short cable into said second high-performance termination;d. applying a defined test load to said second short cable, wherein saiddefined test load is applied through said second advanced termination inorder to determine whether said second short cable and said secondadvanced, termination pass a defined test criterion; and e. after saidsecond short cable passes said defined test criterion, joining saidfirst end of said second short cable to said first end of said longcable.